JP7263838B2 - Modeling method of three-dimensional object - Google Patents

Description

The present disclosure relates to a method of forming a three-dimensional structure.

For example, Patent Literature 1 discloses a method of manufacturing a metal powder sintered component in which a plurality of sintered layers are laminated by irradiating a layer of metal powder with a laser to sinter the layer. In this method, after the sintered layer is formed to be larger than the desired shape by a predetermined dimension, unnecessary portions of the sintered layer are removed by cutting.

JP-A-2003-313604

As in the method described above, when creating a three-dimensional model by removing unnecessary parts from the formed layer by cutting, the cutting tool does not reach the unnecessary parts, creating a three-dimensional model with the desired shape. Sometimes I can't. For example, when creating a tubular three-dimensional model that is longer than the cuttable length of a cutting tool, the cutting tool does not reach the inner peripheral surface of the tube, making it impossible to create a three-dimensional model with a desired shape. Therefore, an object of the present application is to improve the degree of freedom in the shape of a three-dimensional model created by laminating modeling materials and cutting.

According to one aspect of the present disclosure, there is provided a method of forming a three-dimensional structure using a cutting tool capable of cutting up to a first length in a predetermined cutting direction. This method of forming a three-dimensional structure comprises: a first part forming step of forming a first part having a length along a first direction that is shorter than the first length by layering a forming material; a first end face in the first direction of the first portion by laminating the first portion cutting step of cutting the first portion with the cutting tool along the first direction; A second partial shaping step of shaping a second part whose length along the second direction is shorter than the first length, and the cutting tool with the cutting direction along the second direction, and a second portion cutting step of cutting the second portion along the second direction.

Explanatory drawing which shows schematic structure of the three-dimensional modeling apparatus in 1st Embodiment. FIG. 4 is an explanatory diagram showing a schematic configuration of an ejection unit according to the first embodiment; The perspective view which shows the structure of the groove|channel formation surface of the flat screw in 1st Embodiment. The top view which shows the structure of the screw opposing surface of the barrel in 1st Embodiment. 4 is a flowchart showing the contents of data generation processing in the first embodiment; The perspective view which shows the 1st shape in 1st Embodiment. The perspective view which shows the 2nd shape in 1st Embodiment. The perspective view which shows the 3rd shape in 1st Embodiment. Explanatory drawing which shows typically a shaping|molding path|pass and a cutting path|pass. Explanatory drawing which shows typically the data for modeling, and the data for cutting. 4 is a flowchart showing the details of modeling processing in the first embodiment; 4A to 4C are process diagrams showing a first partial molding process in the first embodiment; XIII-XIII line cross-sectional view of the first portion. FIG. 4 is a process drawing showing a first partial cutting process in the first embodiment; The process drawing which shows the 1st heating process in 1st Embodiment. FIG. 5 is a process drawing showing a second partial molding process in the first embodiment; FIG. 5 is a process drawing showing a second partial cutting process in the first embodiment; Process drawing which shows the 2nd heating process in 1st Embodiment. FIG. 7 is a process drawing showing a third partial molding process in the first embodiment; FIG. 5 is a process diagram showing a third partial cutting process in the first embodiment; A first explanatory view showing a three-dimensional structure as another form. A second explanatory view showing a three-dimensional structure as another form. FIG. 5 is an explanatory diagram showing a schematic configuration of a discharge unit as another form;

A. First embodiment:
FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus 10 according to the first embodiment. In FIG. 1, arrows along the mutually orthogonal X, Y, and Z directions are shown. The X and Y directions are along the horizontal direction, and the Z direction is along the vertical direction. Also in other figures, arrows along the X, Y, and Z directions are shown as appropriate. The X, Y, Z directions in FIG. 1 and the X, Y, Z directions in other drawings represent the same directions.

A three-dimensional modeling apparatus 10 in this embodiment includes a discharge unit 100 , a cutting unit 200 , a stage 300 , a moving mechanism 400 and a control section 500 . The information processing device 15 is connected to the control unit 500 . The three-dimensional modeling apparatus 10 and the information processing apparatus 15 can be collectively regarded as a three-dimensional modeling apparatus in a broad sense.

Under the control of the control unit 500, the three-dimensional modeling apparatus 10 drives the moving mechanism 400 while ejecting the modeling material from the nozzle 61 provided in the ejection unit 100 toward the modeling surface 310 of the stage 300. By changing the relative positions of the nozzle 61 and the stage 300 , the modeling material is layered on the stage 300 . A detailed configuration of the ejection unit 100 will be described later with reference to FIG. 2 .

In addition, under the control of the control unit 500, the three-dimensional modeling apparatus 10 in the present embodiment rotates the cutting tool 210 attached to the cutting unit 200, drives the moving mechanism 400, and moves the cutting tool 210 and the stage 300. By changing the position relative to , the building material stacked on the stage 300 is cut. The 3D modeling apparatus 10 thus creates a 3D model OB having a desired shape. Note that FIG. 1 schematically shows a three-dimensional structure OB.

The cutting unit 200 is a cutting device that cuts the modeling material stacked on the stage 300 by rotating the cutting tool 210 attached to the shaft at the tip of the head. A flat end mill or a ball end mill, for example, can be used as the cutting tool 210 . The cutting unit 200 detects the position of the tip of the cutting tool 210 using a general position detection sensor and transmits the detection result to the control section 500 . Using this detection result, the control unit 500 performs cutting by controlling the relative positional relationship between the cutting tool 210 and the laminated modeling material by the moving mechanism 400 described later. In addition, the cutting unit 200 may include a static eliminator such as an ionizer.

The moving mechanism 400 changes the relative positions of the discharge unit 100 and cutting unit 200 and the stage 300 . In this embodiment, the moving mechanism 400 moves the stage 300 with respect to the discharge unit 100 and the cutting unit 200 . The moving mechanism 400 in this embodiment is composed of a 3-axis positioner that moves the stage 300 in the 3-axis directions of the X, Y, and Z directions by the driving force of 3 motors. Each motor is driven under control of the control unit 500 . The moving mechanism 400 may be configured to move the ejection unit 100 and the cutting unit 200 without moving the stage 300 instead of moving the stage 300 . The moving mechanism 400 may be configured to move both the discharge unit 100 and the cutting unit 200 and the stage 300 .

The control unit 500 is configured by a computer including one or more processors, a main storage device, and an input/output interface for inputting/outputting signals with the outside. In this embodiment, the control unit 500 exhibits various functions by causing the processor to execute programs and instructions read into the main storage device. Note that the control unit 500 may be configured by a combination of multiple circuits instead of a computer.

The information processing device 15 is configured by a computer including one or more processors, a main memory device, and an input/output interface for inputting/outputting signals with the outside. In this embodiment, the information processing device 15 exhibits various functions as a result of the processor executing programs and instructions read into the main storage device. The information processing device 15 includes a data generator 16 . As will be described later with reference to FIGS. 5 to 10 , the data generation unit 16 generates modeling data and cutting data for the control unit 500 of the three-dimensional modeling apparatus 10 to control the ejection unit 100, the cutting unit 200, and the moving mechanism 400. Generate data for

FIG. 2 is an explanatory diagram showing a schematic configuration of the ejection unit 100 in this embodiment. The discharge unit 100 includes a material supply section 20 , a melting section 30 , a discharge section 60 and a reheating section 70 . A material in the form of pellets, powder, or the like is supplied to the material supply unit 20 . The material in this embodiment is a pellet-shaped ABS resin. The material supply section 20 in this embodiment is configured by a hopper. The material supply section 20 and the melting section 30 are connected by a supply path 22 provided below the material supply section 20 . A material introduced into the material supply section 20 is supplied to the melting section 30 through the supply path 22 .

The melting section 30 includes a screw case 31 , a drive motor 32 , a flat screw 40 and a barrel 50 . The melting unit 30 melts at least part of the solid-state material supplied from the material supply unit 20 into a pasty modeling material having fluidity, and supplies the material to the nozzle 61 . Incidentally, the flat screw 40 may be simply called a screw.

The screw case 31 houses the flat screw 40 . A drive motor 32 is fixed to the upper surface of the screw case 31 . A rotating shaft of the drive motor 32 is connected to the upper surface 41 of the flat screw 40 .

The flat screw 40 has a substantially cylindrical shape whose height in the direction along the central axis RX is smaller than its diameter. The flat screw 40 is arranged inside the screw case 31 so that the central axis RX is parallel to the Z direction. The torque generated by the drive motor 32 rotates the flat screw 40 around the central axis RX within the screw case 31 .

The flat screw 40 has a grooved surface 42 on the side opposite to the upper surface 41 in the direction along the central axis RX. A groove portion 45 is formed in the groove forming surface 42 . A detailed shape of the grooved surface 42 of the flat screw 40 will be described later with reference to FIG.

A barrel 50 is provided below the flat screw 40 . The barrel 50 has a screw facing surface 52 that faces the grooved surface 42 of the flat screw 40 . A heater 58 is incorporated in the barrel 50 at a position facing the groove 45 of the flat screw 40 . The temperature of the heater 58 is controlled by the controller 500 . Note that the heater 58 may also be called a heating section.

A communication hole 56 is provided in the center of the screw facing surface 52 . The communication hole 56 communicates with the nozzle 61 . The detailed shape of the screw facing surface 52 of the barrel 50 will be described later with reference to FIG.

The ejection part 60 has a nozzle 61 . The nozzle 61 is provided with a nozzle channel 65 and a nozzle hole 62 . The nozzle channel 65 communicates with the communication hole 56 of the melting section 30 . The nozzle hole 62 is an opening provided at the tip of the nozzle 61 and communicating with the nozzle flow path 65 . The modeling material supplied from the melting section 30 to the nozzle 61 is discharged from the nozzle hole 62 . In this embodiment, the nozzle 61 is provided with a circular nozzle hole 62 . The diameter of the nozzle hole 62 is called a nozzle diameter Dn. The nozzle 61 is arranged such that the side surface of the tip of the nozzle 61 has an inclination angle θn with respect to the stage 300 . The shape of the nozzle hole 62 is not limited to circular, and may be square or the like.

The reheating unit 70 reheats the modeling material that is laminated on the stage 300 and hardened. In this embodiment, the reheating section 70 is configured by a heater arranged adjacent to the nozzle 61 . The temperature of the reheating section 70 is controlled by the control section 500 .

FIG. 3 is a perspective view showing the configuration of the groove forming surface 42 of the flat screw 40 in this embodiment. The flat screw 40 shown in FIG. 3 is shown in a state in which the vertical positional relationship shown in FIG. 2 is reversed in order to facilitate understanding of the technology. The groove portion 45 is formed in the groove forming surface 42 of the flat screw 40 as described above. The groove portion 45 has a central portion 46 , a spiral portion 47 and a material introduction portion 48 .

The central portion 46 is a circular depression formed around the central axis RX of the flat screw 40 . The central portion 46 faces a communication hole 56 provided in the barrel 50 .

The spiral portion 47 is a groove that spirally extends from the central portion 46 toward the outer periphery of the groove forming surface 42 in an arc. The spiral portion 47 may be configured to extend in an involute curve shape or a spiral shape. One end of the spiral portion 47 is connected to the central portion 46 . The other end of the spiral portion 47 is connected to the material introducing portion 48 .

The material introducing portion 48 is a groove wider than the spiral portion 47 provided on the outer peripheral edge of the groove forming surface 42 . The material introduction part 48 continues to the side surface 43 of the flat screw 40 . The material introduction part 48 introduces the material supplied from the material supply part 20 through the supply path 22 into the spiral part 47 . FIG. 3 shows a configuration in which one spiral portion 47 and a material introducing portion 48 are provided from the central portion 46 of the flat screw 40 toward the outer circumference. A plurality of spiral portions 47 and material introduction portions 48 may be provided toward the end.

FIG. 4 is a top view showing the configuration of the screw facing surface 52 of the barrel 50 in this embodiment. As described above, the communication hole 56 that communicates with the nozzle 61 is formed in the center of the screw facing surface 52 . A plurality of guide grooves 54 are formed around the communication hole 56 in the screw facing surface 52 . Each guide groove 54 has one end connected to a communication hole 56 and spirally extends from the communication hole 56 toward the outer periphery of the screw facing surface 52 . Each guide groove 54 has a function of guiding the modeling material to the communication hole 56 .

FIG. 5 is a flow chart showing the contents of data generation processing in this embodiment. This process is executed by the data generation unit 16 of the information processing device 15 when the user performs a predetermined start operation on the information processing device 15 . In this embodiment, modeling data and cutting data are generated by this process. The modeling data is data for controlling the discharge unit 100 and the moving mechanism 400, which is used for modeling the three-dimensional modeled object OB by the three-dimensional modeler 10. FIG. The data for cutting is data for controlling the cutting unit 200 and the moving mechanism 400 used for cutting the three-dimensional structure OB by the three-dimensional structure forming apparatus 10 .

FIG. 6 is a perspective view showing the first shape SP1 represented by the first shape data in this embodiment. 5 and 6, first, in step S110, the data generator 16 acquires first shape data representing the first shape SP1. The first shape SP1 is a shape representing a three-dimensional structure OB created using three-dimensional CAD software or three-dimensional CG software. In other words, it can be said that the first shape SP1 is the designed shape of the three-dimensional structure OB. For the first shape data, for example, data in STL format, IGES format, or STEP format can be used. The data generator 16 can acquire the first shape data created on the information processing device 15 using three-dimensional CAD software, for example. The data generator 16 may acquire the first shape data created outside the information processing device 15 via a recording medium such as a USB memory. In this embodiment, the first shape SP1 has a tubular shape. The first shape SP1 has a bent portion 810, which is a bent portion of the tube, and a straight portion 820, which is a straight portion of the tube. The first shape SP1 has an inner wall surface 825 inside the tube.

In step S<b>120 , the data generation unit 16 sets the position and orientation of the three-dimensional structure OB represented by the first shape SP<b>1 on the stage 300 . The data generator 16 sets the position and orientation of the first shape SP1 on the stage 300 according to, for example, the position and orientation specified by the user. In the present embodiment, the position and orientation of the first shape SP1 on the stage 300 are set such that the central axis CL of the linear portion 820 is parallel to the X direction.

FIG. 7 is a perspective view showing the second shape SP2 represented by the second shape data in this embodiment. In FIG. 7, the modeling surface 310 of the stage 300 is represented by a two-dot chain line for reference. 5 and 7, in step S130, the data generation unit 16 uses the first shape data and the information on the cutting work performed on the three-dimensional structure OB to obtain the second shape SP2. Generate represented second shape data. The second shape SP2 is the shape of the three-dimensional structure OB obtained by adding the cut portion 903, the support portion 904, and the bulk portion 905 to the first shape SP1. A portion included in the first shape SP1 and included in the second shape SP2 is called a main body portion 902. FIG. The body portion 902 and the cutting portion 903 are collectively called a shaping portion 901 .

The cutting portion 903 is a cutting margin for cutting the three-dimensional structure OB. The data generation unit 16 arranges the cutting part 903 according to, for example, the position and dimensions for cutting specified by the user. In this embodiment, a cutting portion 903 is arranged on the inner wall surface 825 .

The support part 904 is a part for holding the shape of the modeling part 901 when forming the three-dimensional structure OB by laminating the modeling material. The data generator 16, for example, arranges the supporter 904 at a position designated by the user. When forming the three-dimensional structure OB according to the second shape SP2, the data generation unit 16 determines whether the shape of the three-dimensional structure OB can be retained, and the shape of the three-dimensional structure OB can be retained. The data generation unit 16 may arrange the support unit 904 if it is not determined that the In this embodiment, the support portion 904 is arranged so as to support the lower surface of the shaping portion 901 in the linear portion 820 . If the three-dimensional structure OB can be modeled without using the support part 904, the support part 904 may not be provided.

The bulky portion 905 is a portion that separates the cutting portion 903 and the stage 300 in order to suppress interference between the cutting unit 200 and the stage 300 when cutting the three-dimensional structure OB. The data generation unit 16, for example, arranges the bulk part 905 at a position designated by the user. The data generation unit 16 determines whether or not the cutting unit 200 interferes with the stage 300 when removing the cutting portion 903 from the shaping portion 901 shaped according to the second shape SP2 by cutting. and the stage 300 may interfere with each other, the data generator 16 may arrange the bulky portion 905 . In this embodiment, a bulk portion 905 is arranged between the lower surfaces of the modeling portion 901 and the support portion 904 and the stage 300 . If the three-dimensional structure OB can be cut without using the bulky portion 905, the bulky portion 905 may not be provided.

In step S140, the data generator 16 determines whether the length Ls of the cutting portion 903 along the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction. The cuttable length Le means the maximum length that can cut the workpiece in a preset direction. For example, when inserting the cutting tool 210 into the hollow portion from one end of the tube arranged so that the central axis extends along the X direction to cut the cutting allowance provided on the inner wall surface of the tube, The distance along the X direction to the cuttable limit position is the cuttable length Le of the cutting tool 210 in the X direction. Using the second shape data and information about the cutting tool 210, the data generator 16 determines that the length Ls of the cutting portion 903 along the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction. Determine whether or not The X direction is sometimes called the first direction, and the cuttable length Le is sometimes called the cuttable depth or the first length.

FIG. 8 is a perspective view showing the third shape SP3 represented by the third shape data in this embodiment. 5 and 8, when it is determined in step S140 that the length Ls of the cutting portion 903 along the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction, data In step S150, the generation unit 16 uses the second shape data to generate third shape data representing the third shape SP3. The third shape SP3 is the shape of the three-dimensional structure OB divided into a plurality of parts. The data generation unit 16 divides the second shape SP2 so that the length of the cutting part 903 along the X direction of each part is shorter than the cuttable length Le of the cutting tool 210 in the X direction, and divides the second shape SP2 into Set 3 shape SP3.

In this embodiment, the length Ls of the cutting portion 903 along the X direction in the straight portion 820 is longer than the cuttable length Le of the cutting tool 210 in the X direction. Therefore, the data generator 16 divides the second shape SP2 into a first portion 910, a second portion 920, and a third portion 930 to generate a third shape SP3. The first portion 910 is a portion including the bent portion 810 and a portion of the straight portion 820 . The second portion 920 is a portion including part of the straight portion 820 adjacent to the first portion 910 . A third portion 930 is a portion including a portion of the straight portion 820 adjacent to the second portion 920 . The length L1 of the cutting portion 903 along the X direction in the first portion 910, the length L2 of the cutting portion 903 along the X direction in the second portion 920, and the cutting portion along the X direction in the third portion 930 The length L3 of 903 is shorter than the cuttable length Le of the cutting tool 210 in the X direction.

In this embodiment, the data generation unit 16 divides the second shape SP2 on a plane inclined with respect to the stage 300 so that the nozzle 61 and the three-dimensional structure OB do not interfere with each other during modeling. A first end face 911 of the first portion 910 on the second portion 920 side is inclined at an acute angle to the stage 300 , and a second end face 921 of the second portion 920 on the third portion 930 side is at an acute angle to the stage 300 . The second shape SP2 is divided so as to incline to . The data generator 16 divides the second shape SP2 such that the inclination angle θ1 of the first end face 911 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 . The data generator 16 divides the second shape SP2 such that the inclination angle θ2 of the second end surface 921 with respect to the stage 300 is the same as the inclination angle θ1 of the first end surface 911 with respect to the stage 300 .

If it is not determined in step S140 that the length Ls of the cutting portion 903 along the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction, the data generator 16 performs the process of step S150. , and proceed to the next step.

Referring to FIG. 5, in step S160, data generator 16 generates cross-sectional data using the third shape data. The cross-sectional data is data representing a cross-sectional shape when the third shape SP3 is cut along a plane parallel to the modeling surface 310 of the stage 300 . The data generation unit 16 cuts the third shape SP3 at intervals corresponding to the thickness of one layer of the modeling material stacked on the stage 300 by the three-dimensional modeling apparatus 10 to generate a plurality of cross-sectional data. The thickness of one layer of modeling material stacked on the stage 300 by the three-dimensional modeling apparatus 10 is set by the user, for example. If step S150 is omitted and the third shape data is not generated, the data generator 16 generates cross-sectional data using the second shape data.

FIG. 9 is an explanatory diagram schematically showing the modeling pass and the cutting pass generated by the data generation unit 16. As shown in FIG. In FIG. 9, the shaping pass is represented by a solid line, and the cutting pass is represented by a broken line. 5 and 9, in step S170, the data generation unit 16 uses each cross-sectional data to generate a modeling path for creating the three-dimensional structure OB, and uses the third shape data to generate a modeling path. to generate the cutting path. A modeling pass is a scanning path with respect to the stage 300 of the nozzle 61 that moves while discharging the modeling material. A cutting path is a scanning path with respect to the stage 300 of the cutting tool 210 that moves while cutting the layered building material. In the present embodiment, the data generator 16 models a first modeling pass Pm1 for modeling the first portion 910, a second modeling pass Pm2 for modeling the second portion 920, and a third portion 930. a third shaping pass Pm3 for cutting the first portion 910, a first cutting pass Pc1 for cutting the first portion 910, a second cutting pass Pc2 for cutting the second portion 920, and a third portion 930 for cutting A third cutting pass Pc3 is generated.

Referring to FIG. 5, in step S180, data generator 16 generates and outputs modeling data and cutting data. In addition to the above-described modeling pass, the modeling data includes, for example, the discharge amount, which is the flow rate of the modeling material discharged from the nozzle 61, and the rotation speed of the drive motor 32 that rotates the flat screw 40, which is set by the user. , the temperature of the heater 58 of the barrel 50, the temperature of the reheating section 70, and the like. In addition to the above-described cutting path, the cutting data includes, for example, information about the number of revolutions of the cutting tool 210 and the feed rate of the cutting tool 210 set by the user. The data generation unit 16 generates and outputs modeling data and cutting data represented by G code, M code, or the like, for example.

In this embodiment, modeling data and cutting data are expressed in one data. This data includes a first shaping data portion for shaping the first portion 910 , a first cutting data portion for cutting the first portion 910 , and a second cutting data portion for shaping the second portion 920 . A shaping data portion, a second cutting data portion for cutting the second portion 920, a third shaping data portion for shaping the third portion 930, and a third cutting data portion for cutting the third portion 930. 3 cutting data portion. A first shaping data portion, a first cutting data portion, a second shaping data portion, a second cutting data portion, a third shaping data portion, and a third cutting data portion are arranged in this order. is set.

FIG. 10 is an explanatory diagram schematically showing modeling data and cutting data in this embodiment. The modeling data are read and interpreted in order from top to bottom in FIG. FIG. 10 shows the first shaping data portion Dm1 and the first cutting data portion Dc1. A command COM1 for moving the nozzle 61 to coordinates (X, Y, Z)=(110, 50, 20) is set in the first modeling data portion Dm1. This coordinate represents the relative position of nozzle 61 with respect to stage 300 . While moving the nozzle 61 from coordinates (X, Y, Z) = (110, 50, 20) to coordinates (X, Y, Z) = (100, 50, 20), the nozzle 61 moves in this section. In between, a command COM2 is set to discharge 10 units of modeling material from the nozzle 61 . While moving the nozzle 61 from coordinates (X, Y, Z) = (100, 50, 20) to coordinates (X, Y, Z) = (100, 45, 20), the nozzle 61 moves in this section. In between, a command COM3 is set to discharge 5 units of modeling material from the nozzle 61 . The illustration is omitted in the middle, and then the command COM4 is set to end the modeling of the first portion 910 . A command COM5 for moving the cutting tool 210 to coordinates (X, Y, Z)=(200, 50, 20) is set in the first cutting data portion Dc1. Command COM6 to move the cutting tool 210 from coordinates (X,Y,Z)=(200,50,20) to coordinates (X,Y,Z)=(100,50,20) at a feed rate of 10 units. is set. After that, a command COM7 is set to end the cutting of the first portion 910 .

FIG. 11 is a flow chart showing the details of the modeling process for realizing the manufacture of the three-dimensional modeled object OB in this embodiment. This process is performed when the user performs a predetermined start operation on the operation panel provided in the three-dimensional modeling apparatus 10 or the information processing device 15 connected to the three-dimensional modeling apparatus 10. It is executed by the controller 500 of the device 10 .

First, in the data acquisition step of step S210, the control unit 500 acquires modeling data and cutting data from the information processing device 15. FIG. In this embodiment, the control unit 500 acquires modeling data and cutting data from the information processing device 15 through wired communication. The control unit 500 may acquire modeling data and cutting data from the information processing device 15 by wireless communication, or acquire modeling data and cutting data from the information processing device 15 via a recording medium such as a USB memory. Cutting data may be acquired.

Next, in the material generation process of step S220, the control unit 500 controls the rotation of the flat screw 40 and the temperature of the heater 58 built into the barrel 50 to melt the material and generate the modeling material. do. This control is also called material generation control. In the material production process, the material stored in the material supply section 20 is supplied to the material introduction section 48 from the side surface 43 of the rotating flat screw 40 via the supply path 22 . The material supplied into the material introduction section 48 is conveyed into the spiral section 47 by the rotation of the flat screw 40 . Rotation of the flat screw 40 and heating by the heater 58 melt at least a portion of the material conveyed into the spiral portion 47 to produce a pasty modeling material having flowability. The generated modeling material is conveyed through the spiral portion 47 toward the central portion 46 and supplied to the nozzle 61 through the communication hole 56 . The modeling material continues to be generated while the modeling process described below is performed.

In the partial modeling process of step S230, the controller 500 models a layered body in which the modeling material is layered on the stage 300 by controlling the discharge unit 100 and the moving mechanism 400 according to the modeling data. The length of this laminate along the X direction is shorter than the cuttable length Le of the cutting tool 210 in the X direction. This control is called partial molding control. By executing the partial modeling control, the control unit 500 ejects the modeling material from the nozzle 61 toward the stage 300 while changing the relative position between the nozzle 61 of the ejection unit 100 and the stage 300 . to form a laminate. Laminating the modeling material means placing a further modeling material on top of the previously placed modeling material. In addition, laminating the modeling materials also means that the modeling materials are continuously arranged. For example, when the modeling material is continuously arranged on the stage 300 by continuously discharging the modeling material from the nozzle 61, the part of the modeling material arranged in contact with the stage 300 is referred to as one layer. The part of the build material placed on top of the first layer is called the eye and the second layer.

In the partial cutting step of step S240, the control unit 500 controls the cutting unit 200 and the moving mechanism 400 in accordance with the cutting data to use the cutting tool 210 to cut the cutting allowance provided on the laminate in the X direction. cut along This control is called partial cutting control. By executing partial cutting control, the control unit 500 changes the relative position between the cutting tool 210 and the stage 300, and brings the rotating cutting tool 210 into contact with the cutting margin of the laminate, thereby cutting the laminate into a desired shape. It is processed to the dimensions and surface roughness of

In step S250, the control unit 500 determines whether or not the creation of the three-dimensional structure OB is completed. After completion of creation of the three-dimensional object OB means after the completion of modeling of the three-dimensional object OB in accordance with the modeling path indicated in the modeling data, and in accordance with the cutting path indicated in the cutting data. It means after the cutting of the three-dimensional structure OB is completed. The control unit 500 can determine whether or not the creation of the three-dimensional structure OB is completed using the modeling data and the cutting data.

If it is determined in step S250 that the creation of the three-dimensional structure OB has been completed, the control section 500 terminates this process. On the other hand, if it is not determined in step S250 that the creation of the three-dimensional structure OB has been completed, the control unit 500 controls the temperature of the reheating unit 70 in the heating process of step S260 to perform lamination. Heat the end faces of the body. This control is called heating control. The control unit 500 heats the end surface of the laminate using the reheating unit 70 for a predetermined time by executing heating control. The heating time is set according to the type of material and the temperature of the reheating section 70 . For example, the control unit 500 sets the heating time using a map showing the relationship between the temperature of the reheating unit 70 and the heating time. This map can be set by examining the time required for the temperature of the end face of the laminate to reach a predetermined temperature exceeding the glass transition point of the material by a test conducted in advance. Note that the control unit 500 may set the heating time using a function representing the relationship between the temperature of the reheating unit 70 and the heating time instead of using the map.

After the heating process of step S260, the control unit 500 returns the process to step S230 and repeats the processes from step S230 to step S250. The control unit 500 repeats the heating process of step S260, the partial modeling process of step S230, and the partial cutting process of step S240 until it is determined in step S250 that the creation of the three-dimensional structure OB is completed. Thus, the stacked bodies are connected along the X direction, and a three-dimensional structure OB having a length along the X direction longer than the cuttable length Le of the cutting tool 210 in the X direction is formed.

FIG. 12 is a process diagram showing the first partial molding process in this embodiment. The first partial molding process means the first partial molding process. In FIG. 12, the cutting portion 903 is represented by a two-dot chain line. In the first partial modeling process, the control unit 500 performs the partial modeling control in step S230 according to the modeling data, thereby stacking the modeling material on the stage 300 and cutting the cutting portion 903 along the X direction. A laminate whose length L1 is shorter than the cuttable length Le of the cutting tool 210 in the X direction is formed. The layered body that is modeled in the first part-modeling process is the first part 910 . The first portion 910 may also be called a first laminate. The first portion 910 has a first end surface 911 that is an end surface to which the second portion 920 is connected in a second partial molding step, which will be described later. The inclination angle θ1 of the first end face 911 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 . The first portion 910 formed on the stage 300 is hardened by being deprived of heat by the stage 300 and the atmosphere.

FIG. 13 is a cross-sectional view of the first portion 910 taken along line XIII-XIII. The first portion 910 has a shaped portion 901 , a support portion 904 and a bulk portion 905 . In FIG. 13, the shaping portion 901, the support portion 904, and the bulk portion 905 are hatched with different types of hatching. The modeling section 901 has a body section 902 and a cutting section 903 . The support portion 904 is removed after the modeling process is completed. In this embodiment, a support portion 904 is provided so as to support the lower surface of the outer peripheral portion of the shaping portion 901 . Bulky portion 905 is removed after completion of the build process. In this embodiment, a bulk portion 905 is provided between the lower surfaces of the modeling portion 901 and the support portion 904 and the stage 300 .

FIG. 14 is a process diagram showing the first partial cutting process in this embodiment. The first partial cutting process means the first partial cutting process. In the first partial cutting step, the control unit 500 cuts the cutting portion 903 of the first portion 910 by executing the partial cutting control of step S240. In this embodiment, the control unit 500 inserts the cutting tool 210 into the hollow portion of the tubular first portion 910 with the rotation axis of the cutting tool 210 along the X direction, and rotates the cutting tool 210. The cutting portion 903 of the first portion 910 is cut by contacting the cutting portion 903 of the first portion 910 .

FIG. 15 is a process chart showing the first heating process in this embodiment. The first heating step means the first heating step. In the first heating step, controller 500 heats first end surface 911 of first portion 910 by executing the heating control in step S260. The control unit 500 heats the first end face 911 by controlling the temperature of the reheating unit 70 according to the modeling data.

FIG. 16 is a process diagram showing the second partial molding process in this embodiment. The second partial molding process means the second partial molding process. In FIG. 16, the cutting portion 903 is represented by a two-dot chain line. In the second partial modeling process, the control unit 500 performs the partial modeling control in step S230 according to the modeling data, thereby stacking the modeling material on the stage 300 and cutting the cutting portion 903 along the X direction. A laminate whose length L2 is shorter than the cuttable length Le of the cutting tool 210 in the X direction is formed. The layered body that is modeled in the second part-modeling process is the second part 920 . The second portion 920 may also be called a second laminate. The second portion 920 has a second end surface 921 that is an end surface to which the third portion 930 is connected in a third partial molding step, which will be described later. The inclination angle θ2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 . The second portion 920 formed on the stage 300 is hardened by being deprived of heat by the stage 300, the first portion 910, and the atmosphere.

FIG. 17 is a process diagram showing the second partial cutting process in this embodiment. The second partial cutting process means the second partial cutting process. In the second partial cutting step, the control unit 500 cuts the cutting portion 903 of the second portion 920 by executing the partial cutting control of step S240. In this embodiment, the control unit 500 inserts the cutting tool 210 into the hollow portion of the tubular second portion 920 with the rotation axis of the cutting tool 210 along the X direction, and rotates the cutting tool 210. The cutting portion 903 of the second portion 920 is cut by bringing it into contact with the cutting portion 903 of the second portion 910 .

FIG. 18 is a process drawing showing the second heating process in this embodiment. The second heating step means the second heating step. In the second heating step, controller 500 heats second end surface 921 of second portion 920 by executing the heating control in step S260. The control unit 500 heats the second end surface 921 by controlling the temperature of the reheating unit 70 according to the modeling data.

FIG. 19 is a process diagram showing the third partial molding process in this embodiment. The third partial molding process means the second partial molding process. In FIG. 19, the cutting portion 903 is represented by a two-dot chain line. In the third partial modeling step, the control unit 500 connects to the second end surface 921 of the second portion 920 along the X direction by executing the partial modeling control of step S230, and the length along the X direction. A laminate is formed in which L3 is shorter than the cuttable length Le of the cutting tool 210 in the X direction. A layered body that is shaped in the third part shaping process is the third part 930 . The third portion 930 may also be called a third laminate. The third portion 930 formed on the stage 300 is hardened by being deprived of heat by the stage 300, the second portion 920, and the atmosphere.

FIG. 20 is a process diagram showing the third partial cutting process in this embodiment. The third partial cutting process means the third partial cutting process. In the third partial cutting step, the control unit 500 cuts the cutting portion 903 of the third portion 930 by executing the partial cutting control of step S240. In the present embodiment, the control unit 500 inserts the cutting tool 210 into the hollow portion of the tubular third portion 930 with the rotation axis of the cutting tool 210 along the X direction, and rotates the cutting tool 210. The cutting portion 903 of the third portion 930 is cut by bringing the cutting tool 210 to contact the cutting portion 903 of the third portion 930 .

In this embodiment, the control unit 500 ends the modeling process after the third partial cutting process. After the modeling process is completed, the user separates the three-dimensional structure OB from the stage 300, removes the support portion 904 and the bulky portion 905, or sinters the three-dimensional structure OB in a furnace to obtain the design shape. The three-dimensional structure OB is finished according to .

According to the method for forming the three-dimensional structure OB of the present embodiment described above, when cutting is performed after laminating the forming material at once, the control unit 500 prevents the cutting tool 210 from reaching and cutting. Since the three-dimensional structure OB having a shape in which the portion 903 remains is divided into the first portion 910, the second portion 920, and the third portion 930, the desired shape can be obtained without leaving the cut portion 903. A three-dimensional object OB can be created. Therefore, it is possible to improve the degree of freedom in the shape of the three-dimensional structure OB that can be created by laminating the modeling material and cutting. In particular, in the present embodiment, the length Ls along the X direction of the cutting portion 903 provided on the inner wall surface 825 of the three-dimensional structure OB is longer than the cuttable length Le of the cutting tool 210 in the X direction. In the case where the cutting process is performed after laminating the modeling material at once, there is a portion where the cutting tool 210 does not reach and the cut portion 903 remains on the inner wall surface 825 . Therefore, the control unit 500 sets the length L1 along the X direction of the cutting portion 903 in the first portion 910, the length L2 along the X direction of the cutting portion 903 in the second portion 920, and the length L2 along the X direction of the cutting portion 903 in the third portion 930 The three-dimensional structure OB is divided into the first portion 910 and the second portion 920 such that the length L3 of the cutting portion 903 along the X direction is shorter than the cuttable length Le of the cutting tool 210 in the X direction. , and a third portion 930 . Therefore, the three-dimensional structure OB having a desired shape can be created without leaving the cut portion 903 on the inner wall surface 825 .

In the present embodiment, the controller 500 controls the inclination angle θ1 of the first end surface 911 with respect to the stage 300 to be smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 in the first partial molding process. The first part 910 is shaped, and in the second part shaping process, the second part 920 is shaped so that the inclination angle θ2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 . to shape. Therefore, interference between the first portion 910 and the nozzle 61 in the second partial modeling process and interference between the second portion 920 and the nozzle 61 in the third partial modeling process can be suppressed.

In addition, in the present embodiment, the control unit 500 performs the first heating step of heating the first end surface 911 of the first portion 910 between the first partial cutting step and the second partial molding step, and the second portion A second heating step of heating the second end surface 921 of the second portion 920 is performed between the cutting step and the third partial molding step. Therefore, the adhesion between the first portion 910 and the second portion 920 and the adhesion between the second portion 920 and the third portion 930 can be improved. Therefore, it is possible to improve the mechanical strength of the three-dimensional structure OB formed by dividing the first portion 910 to the third portion 930 .

In addition, in this embodiment, the control unit 500 models the bulk part 905 between the modeling unit 901 and the stage 300 in each partial modeling process. Therefore, interference between the cutting unit 200 and the stage 300 in each partial cutting process can be suppressed.

In the present embodiment, a pellet-shaped ABS resin material is used, but various materials such as thermoplastic materials, metal materials, and ceramic materials can be used as materials for the discharge unit 100. A material for modeling a three-dimensional model can also be adopted as the main material. Here, the "main material" means a material that forms the core of the shape of the three-dimensional model, and means a material that accounts for 50% by weight or more of the three-dimensional model. The above-described modeling materials include those obtained by melting the main materials alone, and those obtained by melting some of the components contained together with the main materials and forming a paste.

When a material having thermoplasticity is used as the main material, the molding material is generated by plasticizing the material in the fusion zone 30 . "Plasticizing" means melting a thermoplastic material by applying heat.

As a material having thermoplasticity, for example, any one of the following or a thermoplastic resin material in which two or more are combined can be used.
<Example of thermoplastic resin material>
Polypropylene resin (PP), polyethylene resin (PE), polyacetal resin (POM), polyvinyl chloride resin (PVC), polyamide resin (PA), acrylonitrile-butadiene-styrene resin (ABS), polylactic acid resin (PLA), polyphenylene General-purpose engineering plastics such as sulfide resin (PPS), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, polyethylene terephthalate, polysulfone, polyether sulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, poly engineering plastics such as ether ether ketone (PEEK);

Materials having thermoplasticity may be mixed with additives such as pigments, metals, ceramics, waxes, flame retardants, antioxidants, and heat stabilizers. The thermoplastic material is plasticized and converted into a molten state in the melting section 30 by the rotation of the flat screw 40 and the heating of the heater 58 . Further, the modeling material thus produced hardens due to the drop in temperature after being discharged from the nozzle hole 62 .

It is desirable that the thermoplastic material is heated to a glass transition point or higher and injected from the nozzle hole 62 in a completely molten state. For example, the ABS resin has a glass transition point of approximately 120° C., and preferably approximately 200° C. when injected from the nozzle hole 62 . A heater may be provided around the nozzle hole 62 in order to inject the modeling material in such a high temperature state.

In the ejection unit 100, for example, the following metal materials may be used as main materials instead of the above-described thermoplastic materials. In this case, it is desirable to mix the powder material, which is obtained by powdering the metal material described below, with a component that melts when the modeling material is produced, and then feed the mixture into the melting section 30 .
<Example of metal material>
Magnesium (Mg), iron (Fe), cobalt (Co) or chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni) single metals, or these metals An alloy containing one or more.
<Example of alloy>
Maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy.

In the ejection unit 100, it is possible to use a ceramic material as the main material instead of the metal material described above. Examples of ceramic materials that can be used include oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide and zirconium oxide, and non-oxide ceramics such as aluminum nitride. When the metal material or ceramic material as described above is used as the main material, the modeling material placed on the stage 300 may be hardened by sintering with laser irradiation or hot air, for example.

The powder material of the metal material or the ceramic material that is put into the material supply unit 20 may be a mixed material in which a plurality of types of single metal powders, alloy powders, and ceramic material powders are mixed. Also, the powder material of metal material or ceramic material may be coated with, for example, a thermoplastic resin as exemplified above or another thermoplastic resin. In this case, the thermoplastic resin may be melted in the melting section 30 to exhibit fluidity.

For example, the following solvent can be added to the powder material of the metal material or the ceramic material that is put into the material supply section 20 . The solvent can be used alone or in combination of two or more selected from the following.
<Example of solvent>
Water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, iso-propyl acetate, n-acetic acid acetic esters such as -butyl and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone and acetylacetone; ethanol , propanol, butanol; tetraalkylammonium acetates; dimethylsulfoxide, diethylsulfoxide and other sulfoxide solvents; pyridine, γ-picoline, 2,6-lutidine and other pyridine solvents; tetraalkylammonium acetates (e.g., tetrabutylammonium acetate, etc.); ionic liquids such as butyl carbitol acetate, etc.;

In addition, for example, the following binders can be added to the powder materials of metal materials and ceramic materials that are supplied to the material supply unit 20 .
<Binder example>
Acrylic resin, epoxy resin, silicone resin, cellulose resin or other synthetic resin or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyetheretherketone) or other thermoplastic resin.

B. Other embodiments:
(B1) In each embodiment described above, in the first heating step, the control unit 500 uses the reheating unit 70 to heat the first end face 911 of the first portion 910, and in the second heating step, Control unit 500 heats second end surface 921 of second portion 920 using reheating unit 70 . On the other hand, the first heating process and the second heating process may not be performed.

(B2) In the above-described embodiment, in the first heating step, the control unit 500 uses the reheating unit 70 to heat the first end face 911 of the first portion 910 for a predetermined time, and in the second heating step, , the control unit 500 uses the reheating unit 70 to heat the second end surface 921 of the second portion 920 for a predetermined time. On the other hand, in each heating process, the control unit 500 may heat the end surfaces 911 and 921 using the reheating unit 70 until the end surfaces 911 and 921 reach a predetermined temperature. For example, the control unit 500 acquires the temperatures of the end surfaces 911 and 921 using temperature sensors, and when the acquired temperatures reach a predetermined temperature equal to or higher than the glass transition point of the material, the reheating unit 70 starts heating. You can stop. In this case, the adhesion between the portions 910 to 930 can be improved more reliably. As the temperature sensor, for example, a contact thermometer such as a thermocouple or a non-contact thermometer such as an infrared thermometer can be used. The predetermined temperature is preset according to the type of material.

(B3) In the above-described embodiment, the controller 500 causes the inclination angle θ1 of the first end surface 911 with respect to the stage 300 to be smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 in the first partial molding process. In the second part molding process, the second part 910 is molded so that the inclination angle θ2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300 . Shaping portion 920 . On the other hand, in each part forming process, the control unit 500 may form the parts 910 and 920 so that the end faces 911 and 921 are equal to or larger than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300. . In this case, for example, in the first cutting step, cutting is performed so that the inclination angle θ1 of the first end surface 911 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300, whereby the Interference between the first portion 910 and the nozzle 61 in the two-part molding process can be suppressed. Further, in the second cutting step, cutting is performed so that the inclination angle θ2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θn of the side surface of the nozzle 61 with respect to the stage 300, whereby the third partial molding is performed. Interference between the second portion 920 and the nozzle 61 in the process can be suppressed.

(B4) In the above-described embodiment, the length Ls along the X direction of the cutting portion 903 provided on the inner wall surface 825 of the three-dimensional structure OB is longer than the cuttable length Le of the cutting tool 210 in the X direction. long. On the other hand, the length Ls of the cutting portion 903 along the X direction may be shorter than the cuttable length Le of the cutting tool 210 in the X direction.

(B5) In the above-described embodiment, in the data generation process, the data generation unit 16 determines that the lengths L1 to L3 of the cutting portion 903 along the X direction of the respective portions 910 to 930 are the lengths of the cutting tool 210 in the X direction. The second shape SP2 is divided so as to be shorter than the cuttable length Le. On the other hand, the data generator 16 sets the lengths L1 to L3 of the cutting portion 903 along the X direction of the respective portions 910 to 930 to be shorter than the cuttable length Le of the cutting tool 210 in the X direction. You may divide the build pass into Even in this case, if the cutting process is performed after the building material is laminated at once, the three-dimensional structure OB having a shape in which the cutting tool 210 cannot reach and the cutting part 903 remains is the first part. 910, a second portion 920, and a third portion 930 can be divided.

(B6) FIG. 21 is an explanatory diagram showing a three-dimensional structure OB2 as another form. FIG. 21 shows the three-dimensional structure OB2 after the third partial modeling process and before the third partial cutting process. The three-dimensional structure OB2 has a straight tubular shape. The three-dimensional structure OB2 is arranged on the stage 300 such that the central axis CL of the tube is parallel to the Z direction. A cut portion 903 is provided on the inner wall surface 825 of the pipe in the three-dimensional structure OB2. Since the length Ls along the Z direction of the cutting part 903 provided in the three-dimensional structure OB2 is longer than the cuttable length Le of the cutting tool 210 in the Z direction, the cutting process is performed after laminating the modeling material at once. When the three-dimensional structure OB2 is created by applying the cutting tool 210, there is a portion where the cutting part 903 remains. Therefore, the control unit 500 determines the length L1 along the Z direction of the cutting portion 903 in the first portion 910b, the length L2 along the Z direction of the cutting portion 903 in the second portion 920b, and the length L2 along the Z direction in the third portion 930b. The three-dimensional structure OB2 is divided into the first portion 910b and the second portion 920b such that the length L3 of the cutting portion 903 along the Z direction is shorter than the cuttable length Le of the cutting tool 210 in the Z direction. and the third portion 930b. Therefore, a three-dimensional structure OB2 having a desired shape can be created without leaving the cut portion 903. FIG.

(B7) FIG. 22 is an explanatory diagram showing a three-dimensional structure OB3 as another form. FIG. 22 shows the three-dimensional structure OB3 after the third partial modeling process and before the third partial cutting process. The three-dimensional structure OB3 has a bent tubular shape. The three-dimensional structure OB3 is arranged on the stage 300 such that the central axis CL of the tube is parallel to the stage 300. As shown in FIG. The three-dimensional structure OB3 has a portion that extends in a first direction parallel to the X direction and a portion that intersects the X direction and extends in a second direction parallel to the stage 300, in order from one end. and a portion extending in the first direction. A cut portion 903 is provided on the inner wall surface 825 of the pipe in the three-dimensional structure OB3. The length Ls along the first direction of the cutting portion 903 provided on the three-dimensional structure OB3 is longer than the cuttable length Le of the cutting tool 210 in the first direction. Since the three-dimensional structure OB3 has a curved tubular shape, when the three-dimensional structure OB3 is created by laminating the modeling materials at once and then performing cutting, the cutting tool 210 cannot reach the three-dimensional structure OB3. A portion where the cut portion 903 remains is generated. Therefore, the control unit 500 moves the three-dimensional structure OB3 so that the first portion 910c, the second portion 920c, and the third portion 930c each form a straight tubular shape. 920c and the third part 930c are divided. At this time, the control unit 500 determines that the length L1 along the first direction of the cutting portion 903 in the first portion 910c is shorter than the cuttable length Le in the first direction of the cutting tool 210, and The length L2 of the cutting portion 903 along the second direction is shorter than the cuttable length Le of the cutting tool 210 in the second direction, and the length L3 of the cutting portion 903 along the first direction at the third portion 930c is The three-dimensional structure OB3 is divided into a first portion 910c, a second portion 920c, and a third portion 930c so as to be shorter than the cuttable length Le of the cutting tool 210 in the first direction. Therefore, a three-dimensional structure OB3 having a desired shape can be created without leaving the cut portion 903. FIG.

(B8) FIG. 23 is an explanatory diagram showing a schematic configuration of a discharge unit 100b as another form. The discharge unit 100b may comprise a melt section 30b having an in-line screw 140 and a barrel 50b. The in-line screw 140 has a substantially cylindrical shape whose length in the direction along the central axis RX is greater than its diameter. The in-line screw 140 is arranged such that the central axis RX is parallel to the Z direction. A spiral groove 145 is provided on the side surface of the column of the in-line screw 140 . The in-line screw 140 is rotated by a drive motor 32 connected to its upper end. The barrel 50b has a cylindrical shape that covers the outer circumference of the in-line screw 140. As shown in FIG. The barrel 50b is provided with a screw facing surface 52b facing the in-line screw 140 on the inner wall surface of the cylinder. A heater 58b is incorporated in the barrel 50b at a position facing the groove 145 of the in-line screw 140. As shown in FIG. A communication hole 56 is formed on the central axis RX of the in-line screw 140 in the cylindrical bottom surface of the barrel 50b. Even in this form, the melting section 30b melts the material supplied from the material supply section 20 to the groove section 145 by the rotation of the in-line screw 140 and the heating by the heater 58b to generate the forming material, thereby forming the communication hole. 56. In addition, the in-line screw 140 may be simply called a screw. The heater 58b may also be called a heating section.

C. Other forms:
The present disclosure is not limited to the embodiments described above, and can be implemented in various forms without departing from the scope of the present disclosure. For example, the present disclosure can also be implemented in the following forms. The technical features in the above embodiments corresponding to the technical features in each form described below are used to solve some or all of the problems of the present disclosure, or to achieve some or all of the effects of the present disclosure. In order to achieve the above, it is possible to appropriately replace or combine them. Also, if the technical features are not described as essential in this specification, they can be deleted as appropriate.

(1) According to a first aspect of the present disclosure, there is provided a three-dimensional object modeling method using a cutting tool capable of cutting up to a first length in a predetermined cutting direction. This method of forming a three-dimensional structure comprises: a first part forming step of forming a first part having a length along a first direction that is shorter than the first length by layering a forming material; a first end face in the first direction of the first portion by laminating the first portion cutting step of cutting the first portion with the cutting tool along the first direction; A second partial shaping step of shaping a second part whose length along the second direction is shorter than the first length, and the cutting tool with the cutting direction along the second direction, and a second portion cutting step of cutting the second portion along the second direction.
According to the method for forming a three-dimensional structure of this embodiment, when cutting is performed after laminating the forming material at once, the three-dimensional structure is produced in such a way that there is a portion where the cutting tool cannot reach and the cutting allowance remains. A desired shape can be created without leaving any cutting allowance. Therefore, it is possible to improve the degree of freedom in the shape of the three-dimensional model that can be created by laminating the modeling material and cutting.

(2) In the method for forming a three-dimensional structure according to the above aspect, the first direction and the second direction may be the same direction.
According to this aspect of the method for forming a three-dimensional structure, it is possible to create a three-dimensional structure in a desired shape in which the cutting allowance is provided along the first direction.

(3) In the method for forming a three-dimensional structure according to the above aspect, the first direction and the second direction may be different directions.
According to the method for forming a three-dimensional structure of this aspect, it is possible to create a three-dimensional structure in a desired shape, in which a cutting tool does not reach a portion by cutting only from one direction, and a cutting allowance remains.

(4) In the method for forming a three-dimensional structure according to the aspect described above, the total length of the first portion and the second portion in the first direction and the first portion and the second portion in the second direction are and at least one of the combined length may be longer than the first length.
According to the method for forming a three-dimensional structure of this aspect, it is possible to create a three-dimensional structure in a desired shape, which has a long shape and thus has a portion that is not reached by the cutting tool and leaves a cutting allowance.

(5) In the method for forming a three-dimensional structure according to the above aspect, the inclination angle of the first end surface of the first portion with respect to the stage on which the modeling material is stacked is such that the side surface of the nozzle for discharging the modeling material is: It may be smaller than the tilt angle with respect to the stage.
According to the method for forming a three-dimensional structure of this aspect, it is possible to suppress interference between the nozzle and the first portion when forming the second portion connected to the first portion.

(6) The method for forming a three-dimensional structure according to the aspect described above may include a heating step of heating the first end surface of the first portion prior to the second partial forming step.
According to the three-dimensional structure modeling method of this aspect, the adhesion between the first portion and the second portion can be improved, so that the mechanical strength of the three-dimensional structure can be improved.

(7) In the method of forming a three-dimensional structure according to the aspect described above, the first portion is formed in contact with a stage, and the stage and the cutting margin cut in the first portion cutting step of the first portion are combined. It may have a bulky part to ensure the distance of
According to the method for forming a three-dimensional structure of this aspect, it is possible to suppress interference between the device used for cutting and the stage when cutting the first portion.

The present disclosure can also be realized in various forms other than the three-dimensional structure modeling method. For example, it can be implemented in the form of a three-dimensional modeling apparatus, a method of controlling a three-dimensional modeling apparatus, a data generating apparatus, a data generating method, and the like.

DESCRIPTION OF SYMBOLS 10... Three-dimensional modeling apparatus, 15... Information processing apparatus, 16... Data generation part, 20... Material supply part, 22... Supply path, 30, 30b... Melting part, 31... Screw case, 32... Drive motor, 40... Flat Screw 41 Upper surface 42 Groove formation surface 43 Side surface 45 Groove 46 Central portion 47 Spiral portion 48 Material introduction portion 50, 50b Barrel 52, 52b Screw facing surface, 54 Guide groove 56 Communication hole 58, 58b Heater 60 Discharge part 61 Nozzle 62 Nozzle hole 65 Nozzle flow path 70 Reheating part 100, 100b Discharge unit 140 In-line screw 145 Groove 200 Cutting unit 210 Cutting tool 300 Stage 310 Molding surface 400 Moving mechanism 500 Control unit 810 Bent portion 820 Linear portion 825 Inside Wall surface 901 Modeling portion 902 Body portion 903 Cutting portion 904 Supporting portion 905 Bulk portion 910, 910b, 910c First portion 911 First end surface 920, 920b, 920c Third 2 parts, 921... second end face, 930, 930b, 930c... third part

Claims (7)

A method for forming a three-dimensional structure using a cutting tool capable of cutting a maximum of a first length in a predetermined cutting direction,
By layering the modeling material discharged from the nozzle in a layering direction perpendicular to the layering surface of the stage , a first portion having a length along a first direction intersecting the layering direction that is shorter than the first length is modeled. a first partial molding step;
a first portion cutting step of cutting the first portion along the first direction with the cutting tool having the cutting direction along the first direction ;
By stacking the modeling material discharged from the nozzle in the stacking direction , the first portion is connected to the first end face in the first direction and has a length along the second direction intersecting the stacking direction. a second part shaping step of shaping a second part shorter than the first length;
a second partial cutting step of cutting the second portion along the second direction with the cutting tool having the cutting direction along the second direction;
has
The inclination angle of the first end surface with respect to the modeling surface is smaller than the inclination angle of the side surface of the nozzle with respect to the stage in the second partial modeling step.
A method of forming a three-dimensional object. The method for forming a three-dimensional structure according to claim 1,
A method of forming a three-dimensional structure, wherein the first direction and the second direction are the same direction. The method for forming a three-dimensional structure according to claim 1,
A method for forming a three-dimensional structure, wherein the first direction and the second direction are different directions. The method for forming a three-dimensional structure according to any one of claims 1 to 3,
At least one of the combined length of the first portion and the second portion in the first direction and the combined length of the first portion and the second portion in the second direction A method for forming a three-dimensional model longer than one length. The method for forming a three-dimensional structure according to any one of claims 1 to 4,
The first portion has a tubular shape with an inner wall surface extending along the first direction,
In the first partial cutting step, the inner wall surface of the first portion is cut along the first direction,
The second portion has a tubular shape with an inner wall surface extending along the second direction,
In the second partial cutting step, the method of forming a three-dimensional structure, wherein the inner wall surface of the second portion is cut along the second direction. The method for forming a three-dimensional structure according to any one of claims 1 to 5,
A method for forming a three-dimensional structure, comprising a heating step of heating the first end face of the first portion prior to the second partial forming step. The method for forming a three-dimensional structure according to any one of claims 1 to 6,
The first portion is shaped in contact with the stage, and has a three-dimensional portion for securing a distance between the stage and a cutting allowance cut in the first portion cutting step in the first portion. Modeling method.

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